Page 113 of 1771
Piston Pins
Inspection
1. Measure the diameter of the piston pin.
Piston Pin Diameter:
Standard (New): 21.994 - 22.000 mm
(0.8659 - 0.8661 in)
Oversize: 21.997 - 22.003 mm
(0.8660 - 0.8663 in)
NOTE: All replacement piston pins are oversize.
2. Zero the dial indicator to the piston pin diameter.
3. Measure the piston pin-to-piston clearance.
NOTE: Check the piston for distortion or cracks.
If the piston pin clearance is greater then 0.024 mm
(0.0009 in), remeasure using an oversize piston pin.
Piston Pin-to-Piston Clearance:
Standard (New): 0.010 - 0.019 mm
(0.0004 - 0.0007 in)
4. Check the difference between the piston pin diame-
ter and connecting rod small end diameter.
Piston Pin-to-Connecting Rod Interference:
Standard (New): 0.013 - 0.032 mm
(0.0005 - 0.0013 in)ProCarManuals.com
Page 114 of 1771

Piston Ring s
End Ga pReplacemen t
1. Usin g a piston , pus h a ne w rin g int o th e cylinde r
bor e 15-2 0 m m (0. 6 - 0. 8 in ) fro m th e bottom .
2 . Measur e th e pisto n rin g end-ga p wit h a feele r
gauge:
If th e ga p is to o small , chec k to se e if yo u hav e th e
prope r ring s fo r you r engine .
I f th e ga p i s to o large , rechec k th e cylinde r bor e
diamete r agains t th e wea r limit s o n pag e 7-13 .
I f th e bor e i s ove r th e servic e limit , th e cylinde r
bloc k mus t b e rebored .
Pisto n Rin g End-Gap :
To p Rin g
Standar d (New) : 0.2 5 - 0.4 0 m m
(0.010-0.01 6 in )
Servic e Limit : 0.7 0 m m (0.02 8 in )
Secon d Rin g
Standar d (New) : 0.4 0 - 0.5 5 m m
(0.016-0.02 2 in )
Servic e Limit : 0.8 5 m m (0.03 3 in )
Oi l Rin g
Standar d (New) : 0.2 0 - 0.7 0 m m
(0.00 8 - 0.02 8 in ) * 1
0.2 0 - 0.5 0 mm
(0.00 8 - 0.02 0 in ) * 2
Servic e Limit : 0.8 0 m m (0.03 1 in )
*1 : RIKE N manufacture d pisto n ring .
*2 : TEIKOK U PISTO N RIN G manufacture d pisto n ring . 1
. Usin g a rin g expander , remov e th e ol d pisto n rings .
2 . Clea n al l rin g groove s thoroughly .
NOTE:
Use a squared-of f broke n rin g o r rin g groov e
cleane r wit h blad e t o fi t th e pisto n grooves . Fil e
dow n blad e if necessary .
To p an d 2n d rin g groove s ar e 1. 2 m m (0.0 5 in )
wid e an d oi l rin g groov e i s 2. 8 m m (0.1 1 in )
wide .
CAUTION : D o no t us e a wir e brus h to clea n th e rin g
grooves , o r cu t rin g groove s deepe r wit h th e clean -
in g tool .
NOTE : I f th e pisto n is t o b e separate d fro m th e con -
nectin g rod , d o no t instal l ne w ring s yet .
3 . Instal l ne w ring s i n prope r sequenc e an d positio n
(page 7-18 ).
NOTE : D o no t reus e ol d pisto n rings .
PISTO N RIN G
RING EXPANDE R(Commerciall y available )
PISTO N RIN G
END GA P
15 - 2 0 m m(0.6 -0. 8 in)
ProCarManuals.com
Page 115 of 1771

Piston Ring s
Ring-to-Groov e Clearanc e
After installin g a ne w se t o f rings , measur e th e ring-to -
groov e clearance :
To p Rin g Clearanc e
Standar d (New) : 0.05 5 - 0.08 0 m m
(0.002 2 - 0.003 1 in )
Servic e Limit : 0.1 3 m m (0.00 5 in )
Secon d Rin g Clearanc e
Standar d (New) : 0.03 0 - 0.05 5 m m
(0.001 2 - 0.002 2 in )
Servic e Limit : 0.1 3 m m (0.00 5 in )
FEELE R GAUG E
Alignmen t
1. Instal l th e ring s a s show n o n pag e 7-17 .
Identif y th e to p an d secon d ring s b y th e chamfe r o n
th e edge . Mak e sur e the y ar e in th e prope r groove s o n
th e piston .
NOTE : Th e manufacturin g mark s mus t b e facin g
upward .
TOP RIN G
SECON D RIN G
MAR K
TOP RIN G
SECON D RIN GMAR K
SPACE R
2. Rotat e th e ring s i n th e groove s t o mak e sur e the y d o
no t bind .
3. Positio n th e rin g en d gap s a s shown :
SECON D RIN G GA P D
O NO T positio n an y rin g ga p
a t pisto n thrus t surfaces .
OI L RIN G
GAP
TOP RIN G GA P
DO NO T positio n an y rin g ga pin lin e wit h pisto n pi n hole .
SPACE R GA P
OIL RIN GGAP
OIL RIN G
ProCarManuals.com
Page 116 of 1771

Pistons
Installation
Before installing the piston, apply a coat of engine
oil to the ring grooves and cylinder bores.
1. If the crankshaft is already installed:
Guide the piston carefully to prevent damage.
Fit long rubber hoses (about 30 cm (12 in) long) to
the connecting rod bolts to protect the crankshaft.
Install the pistons after setting the crankshaft to
BDC for each cylinder.
INCORRECT
CORRECT
RUBBER HOSES
Remove the connecting rod caps, then slip the
long rubber hoses over the threaded ends of the
connecting rod bolts.
Install the ring compressor, check that the bear-
ing is securely in place; then position the piston
in the cylinder and tap it in using the wooden
handle of a hammer.
Stop after the ring compressor pops free, and
check the connecting rod-to-crank journal align-
ment before pushing the piston into place.
Install the rod caps with bearings, and torque the
nuts to 44 N-m (4.5 kgf-m, 33 Ibf-ft).
2. If the crankshaft is not installed:
Remove the rod caps and bearings, install the
ring compressor, then position the piston in the
cylinder and tap it in using the wooden handle of
a hammer.
The arrow must face
the timing belt side
of the engine and the
connecting rod oil hole
must face the right side
of the engine.
CONNECTING ROD
OIL HOLE
RUBBER
HOSE
NOTE: Maintain downward force on the ring com-
pressor to prevent rings from expanding before
entering the cylinder bore.
Use the wooden handle
of a hammer to push, or
tap the piston into the
cylinder bore.
RING COMPRESSOR
(Commercially available)ProCarManuals.com
Page 117 of 1771
Crankshaft Oi l Sea l
Installatio n
The sea l surfac e o n th e bloc k shoul d b e dry .
Appl y a ligh t coa t o f oi l t o th e crankshaf t an d t o
th e li p o f th e oi l seal .
1 . Usin g th e specia l tool , driv e th e crankshaf t oi l sea l
int o th e rea r cover .
REAR COVE R
DRIVE R
07749-001000 0
DRIVER Instal l oi l sea l wit h th eATTACHMEN T par t numbe r sid e07948-SB0010 1 facing out .
2. Confir m tha t th e clearanc e i s equa l al l th e wa y
aroun d wit h a feele r gauge .
Clearance : 0. 2 - 0. 5 m m (0.0 1 - 0.0 2 in )
0.2 — 0.5 m m(0.0 1 — 0.02 in)
REA RCOVE R
REAR COVE R CRANKSHAF
T OI L
SEA L
NOTE : Refe r t o page s 7-2 5 an d 8-1 2 fo r installatio n
of th e oi l pum p sid e oi l seal .
ProCarManuals.com
Page 118 of 1771
Crankshaft
Installation
Before installing the crankshaft, apply a coat of
engine oil to the main bearings and rod bearings.
1. Insert the bearing halves in the cylinder block and
connecting rods.
2. Lower the crankshaft into the block.
3. Install the thrust washers on the No. 4 journal. Oil
the thrust washer surfaces.
THRUST WASHERS
Grooved sides face
outward.ProCarManuals.com
Page 119 of 1771
4. Instal l th e bearing s an d caps . Torqu e th e ca p bolts .
BEARIN G CAP S
TIMIN G BEL TSIDE
CA P BOL T
9 x 1.2 5 mm39 N- m (4. 0 kgf-m ,
2 9 Ibf-ft )
RUBBE R
CAP
JOURNA L NUMBE R
CAP BOLT S11 x 1. 5 m m76 N- m (7. 8 kgf-m ,
5 6 Ibf-ft )
BEARIN G CA P
MAIN BEARIN G
SIDE CA P BOL T10 x 1.2 5 mm49 N- m (5. 0 kgf-m ,
3 6 Ibf-ft ) SHOR
T
LON G BOLT S
BOL T
5. Chec k th e connectin g ro d bearin g clearanc e wit h
plastigag e (se e pag e 7-7 ), the n torqu e th e connect -
in g ro d ca p nuts .
NOTE : Referenc e number s o n th e connectin g rod s
ar e fo r big-en d bor e toleranc e an d d o NO T indicat e
th e positio n o f th e pisto n i n th e engine .
9 x 0.7 5 mm44 N- m (4. 5 kgf-m ,
3 3 Ibf-ft )
• Lin e u p th e mar k whe ninstallin g th e connectin grod cap .
LON GBOLT
ProCarManuals.com
Page 120 of 1771

Crankshaft
BEARING CAP BOLTS TORQUE SEQUENCE
CAUTION: Whenever any crankshaft bearing or con-
necting rod bearing is replaced, it is necessary after
reassembly to run the engine at idling speed until it
reaches normal operating temperature, then contin-
ue to run it for approximately 15 minutes.
9. Apply liquid gasket to the cylinder block mating sur-
face of the rear cover, then install it on the cylinder
block.
REAR COVER
Apply liquid gasket
along the broken line.
Do not apply liquid gasket
to O-ring groove.
NOTE:
Use liquid gasket, Part No. 08718 - 0001 or 08718
- 0003.
Check that the mating surfaces are clean and dry
before applying liquid gasket.
Apply liquid gasket evenly, being careful to cover
all the mating surface.
To prevent oil leakage, apply liquid gasket to the
inner threads of the bolt holes.
Do not apply liquid gasket to O-ring grooves.
Do not install the parts if five minutes or more
have elapsed since applying liquid gasket.
Instead reapply liquid gasket after removing old
residue.
After assembly, wait at least 30 minutes before
filling the engine with oil.
Installation (cont'd)
6. Tighten the 9 x 1.25 mm cap bolts to the specified
torque.
Torque: 39 N-m (4.0 kgf-m, 29 Ibf-ft)
7. Tighten the 11 x 1.5 mm cap bolts to the specified
torque.
Torque: 76 N-m (7.8 kgf-m, 56 Ibf-ft)
8. Tighten the 10 x 1.25 mm cap side bolts to the spec-
ified torque.
Torque: 49 N-m (5.0 kgf-m, 36 Ibf-ft)
Coat the bolt thread and seat surfaces with engine
oil.
9 x
1.25
mm
39 N-m (4.0 kgf-m,
29 Ibf-ft)
11 x 1.5 mm
76 N-m (7.8 kgf-m,
56 Ibf-ft)
10 x
1.25
mm
49 N-m (5.0 kgf-m,
36 Ibf-ft)ProCarManuals.com